The Block 5 design changes are principally^[16] driven by upgrades needed for NASA's Commercial Crew program and National Security Space Launch requirements. They include performance upgrades, manufacturing improvements, and "probably 100 or so changes" to increase the margin for demanding customers.^[17]

In April 2017, SpaceX CEO Elon Musk said that Block 5 will feature 7–8% more thrust by uprating the engines (from 176,000 pounds-force (780,000 N) to 190,000 pounds-force (850,000 N) per engine).^[12] Block 5 includes an improved flight control system for an optimized angle of attack on the descent, lowering landing fuel requirements.

For reusability endurance:

• expected to be able to be launched at least 10 times;^[18][19] achieved in 2021^[20]
• up to 100 uses with refurbishment;^[19][18][21]
• a reusable heat shield protecting the engines and plumbing at the base of the rocket;
• more temperature-resistant cast and machined titanium grid fins;^[22]
• a thermal-protection coating on the first stage to limit reentry heating damage, including a black thermal protection layer on the landing legs, raceway, and interstage;
• redesigned and requalified more robust and longer life valves;
• redesigned composite overwrapped pressure vessels (COPV 2.0) for helium, to avoid oxygen freezing inside the structure of the tanks that lead to rupture.

For rapid reusability:

• reduced refurbishment between flights;^[19]
• a set of retractable landing legs for rapid recovery and shipping.^[23]
• the Octaweb^[24] structure is bolted together instead of welded, reducing manufacturing time.^[25]

Improvements edit

Since the debut of Block 5, SpaceX has continued to iterate on its design, manufacturing processes, and operational procedures.^[26] Among other changes, the initial Block 5 boosters did not have the redesigned composite overwrapped pressure vessel (COPV2) tanks.^[27] The first booster with COPV2 tanks was booster B1047 on the Es'hail 2 mission on November 15, 2018, and the second booster using the COPV2 tanks was CRS-16/B1050, which had its first launch on December 5, 2018.^[28] To improve the rocket's performance, SpaceX has tweaked throttle settings and separation timings.^[26][29] Later Block 5 boosters are also easier to prepare for flight, so SpaceX "prefer to retire" older cores by assigning them to expendable missions when possible.^[30]

Mission extension kits edit

SpaceX CRS-18 featured a Falcon mission-extension kit to the standard second stage, which equipped the second stage with a dark-painted band (for thermal control), extra COPVs for pressurization control, and additional TEA-TEB ignition fluid. The upgrades afforded the second stage with the endurance needed to inject the payloads directly into geosynchronous or high energy orbit where the second stage needs hours after launch.^[31] Based on mission requirements, they are Medium Coast & Long Coast kits, i.e., the number of helium bottles for pressurization and added batteries for power and other hardware to make sure that the fuel and stages systems operate as long as needed.^[32][33]

Merlin 1D Vacuum short nozzle version edit

Transporter-7 mission launch debuted a new Merlin 1D Vacuum nozzle extension design or variant aimed at increasing cadence and reducing costs. This new nozzle extension is shorter and, as a result, decreasing both performance and material usage; but with this nozzle, the engine produces 10% less thrust in space. This nozzle is only used on lower-performance missions, as it decreases the amount of material needed by 75%. This means that SpaceX can launch over three times as many missions with the same amount of rare Niobium metal as with the longer design.^[8][32] As of June 2023, the characteristics of the small nozzle second stage are unknown.

The NASA certification processes of the 2010s specified seven flights of any launch vehicle without major design changes before the vehicle would be NASA-certified for human spaceflight, and allowed to fly NASA astronauts.^[27][28]

The Block 5 design launched astronauts for the first time on May 30, 2020, on a NASA-contracted flight labelled Crew Dragon Demo-2.^[34] This was the first crewed orbital spaceflight launched from the United States since the final Space Shuttle mission in 2011, and the first ever operated by a commercial provider.^[35]

• Falcon 9 Full Thrust, has 1st & 2nd stage specifications
• Falcon Heavy, derivative launcher
• List of Falcon 9 and Falcon Heavy launches
• List of Falcon 9 Block 5 first-stage boosters
• Saturn IB, Apollo crewed LEO launcher (1966-1975)
• SpaceX Starship
• Falcon 9

• Link to Falcon User's Guide, by SpaceX. Updated in January 2019 specifically for Block 5 upgrades.